Manufacturing cell and elements of the cell

ABSTRACT

A manufacturing cell has a plurality of stations arranged in two rows having a main aisle therebetween. Each of the plurality of stations has a station-aisle interface that provides an interaction area to the main aisle. The manufacturing cell also comprises a plurality of storage units that are located within the cell along the main aisle and a guided forklift truck that traverses the main aisle without requiring steering control of a stock handler operating the forklift truck within the main aisle to relocate containers from the storage units to designated station-aisle interfaces and to remove containers from the designated station-aisle interfaces when work is completed at the corresponding stations.

This application is a division of U.S. patent application Ser. No.11/770,479 filed Jun. 28, 2007, entitled MANUFACTURING CELL AND ELEMENTSOF THE CELL, which is incorporated herein in its entirety by reference.

BACKGROUND OF THE INVENTION

The present invention relates in general to manufacturing environments,and in particular, to manufacturing cells for the fabrication,manufacture, processing, assembly and/or subassembly of parts, partassemblies and/or products. The present invention further relates tosystems and methods of configuring and utilizing such manufacturingcells.

Modern manufacturing environments, especially those that supportmultiple, diverse product lines, are constantly challenged with issuesincluding how to accurately forecast demand and how to minimize leadtime from start of manufacture until a completed product is ready to beshipped. This is particularly true for manufacturers of products havingnumerous and/or complex subassemblies.

For example, manufacturers of heavy duty working vehicles, such asforklift trucks, must manufacture and assemble many complex componentsand component assemblies for each model of vehicle that is offered.Moreover, there is extensive labor and time involved in the manufactureof certain component parts of the vehicles, such as covers, doors, etc.,due, at least in part, to the time required to obtain dies, set up jigs,and prepare tools and other necessary specialty items to work on thesecomponent parts. Thus, changeover for manufacturing different componentparts or from the manufacture of component parts associated with a firstproduct line to component parts associated with a second product linecan take considerable time and resources.

Still further, in a manufacturing environment such as for heavy dutyworking vehicles, station operators may be required to interact withcomponents and component part assemblies that are large, heavy and/orawkward to manipulate, which may hinder or otherwise limit the rate atwhich the station operators can perform assigned functions.

BRIEF SUMMARY OF THE INVENTION

According to an aspect of the present invention, a manufacturing cellcomprises a main aisle and a plurality of stations arranged in two rowssuch that the main aisle passes between the two rows. Each of theplurality of stations is configured such that a corresponding stationoperator is capable of performing a predefined function associated withthe manufacturing cell. Moreover, each of the plurality of stations hasa station-aisle interface that provides an interaction area for thestation to the main aisle. The manufacturing cell also comprises aplurality of storage units that are located along the main aisle witheach storage unit being dimensioned to store at least one container. Aforklift truck is automatically guided within the main aisle so that astock handler controlling the truck is able to concentrate on theoperations required to relocate containers within the cell to movecontainers from storage units to designated station-aisle interfaces forinbound workflows to the corresponding stations and to remove containersfrom the designated station-aisle interfaces for outbound workflows fromthe corresponding stations, without being required to also steer thetruck within the main aisle.

According to another aspect of the present invention, a method ofmanufacturing parts using a manufacturing cell comprises storing atleast some components to be used during manufacture on cell containersand storing the cell containers in storage units that are located alonga main aisle which extends between a plurality of stations arranged intwo rows. The method also comprises receiving an order to manufacture apart, using a forklift truck which is automatically guided whiletraversing the main aisle so that a stock handler operating the forklifttruck is not required to provide steering control at least while thetruck is in the main aisle and using the forklift truck for relocatingcell containers from the storage units to designated station-aisleinterfaces for inbound workflows to the corresponding stations and forremoving containers from the designated station-aisle interfaces foroutbound workflows from the corresponding stations, where eachstation-aisle interface provides an interaction area between the mainaisle and a corresponding station.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The following description of illustrated and preferred embodiments ofthe present invention can be best understood when read in conjunctionwith the following drawings, where like structure is indicated with likereference numerals, and in which:

FIG. 1 is a schematic illustration of an exemplary manufacturing cellaccording to various aspects of the present invention;

FIG. 2 is a schematic illustration of a storage unit positioned along amain aisle passageway of the cell of FIG. 1;

FIG. 3 is a schematic illustration of the manufacturing cell of FIG. 1according to various aspects of the present invention;

FIG. 4 is a schematic illustration of the manufacturing cell of FIG. 1that illustrates exemplary conveyor arrangements that may be utilized bystations to move materials, components and component assembliesaccording to various aspects of the present invention;

FIG. 5 is a schematic illustration of a few stations of themanufacturing cell of FIG. 1 that illustrates exemplary conveyorarrangements that may be utilized by stations to move materials,components and component assemblies according to various aspects of thepresent invention;

FIG. 6 is a schematic illustration of an assist for moving heavy workimplements, such as brake press dies, according to an aspect of thepresent invention;

FIG. 7 is a schematic illustration of a system that provides anoperator-assisted system for moving dies into a working position of apress brake according to an aspect of the present invention;

FIG. 8 is a schematic illustration of a conveyor arrangement in a firstposition operatively arranged to transport containers from a main aislepassageway of a manufacturing cell to a work area of a correspondingstation according to various aspects of the present invention;

FIG. 9 is a schematic illustration of the conveyor arrangement of FIG. 8in a second position operatively arranged to transport containers fromthe work area to the corresponding main aisle passageway according tovarious aspects of the present invention;

FIG. 10 is a schematic illustration of an exemplary hydraulic controlfor operating the tilt capabilities of the conveyor of FIGS. 8 and 9according to various aspects of the present invention;

FIG. 11 is a schematic illustration of an exemplary rack, conveyors andtooling for a welding station according to various aspects of thepresent invention;

FIG. 12 is a schematic side view of the arrangement shown in FIG. 11according to various aspects of the present invention;

FIG. 13A is a schematic illustration of an exemplary table arrangementhaving a surface suitable for transferring objects from a correspondingstorage location according to various aspects of the present invention;

FIG. 13B is a schematic illustration of an exemplary table arrangementhaving a scissors-style lifting arrangement to selectively raise andlower a table surface according to various aspects of the presentinvention;

FIG. 14 is a schematic illustration of an exemplary container having acarousel according to an aspect of the present invention;

FIG. 15 is a schematic illustration of an exemplary station illustratinga manipulator useful for moving objects between a conveyor and work areaaccording to an aspect of the present invention;

FIG. 16 is a schematic illustration of two stations, a cell inboundconveyor and an outbound conveyor according to an aspect of the presentinvention;

FIG. 17 is a schematic illustration of a board for monitoring emptiedcontainers according to an aspect of the present invention;

FIG. 18 is a flow chart illustrating an exemplary use of a manufacturingcell according to various aspects of the present invention;

FIG. 19 is a flow chart illustrating exemplary activities performed by aproduction tender as part of a die changeover at a press brake stationaccording to various aspects of the present invention; and

FIG. 20 is a flow chart illustrating exemplary activities performed by aprimary operator as part of a die changeover at a press brake stationaccording to various aspects of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Various aspects of the present invention relate to manufacturing cellsthat allow manufacturers to remain flexible and responsive to marketdemand, while providing manufacturing flexibility and efficiency.

Referring now to the drawings, and particularly to FIG. 1, amanufacturing cell 100 is illustrated according to various aspects ofthe present invention. The manufacturing cell 100 includes a pluralityof stations 102, where each station 102 is assigned a predefinedfunction associated with the manufacturing cell 100. As used herein, the“function” of a given station 102 will be largely defined by themachine(s), tools and/or operations that are performed in that station102. For example, select stations 102 may each be equipped with a pressbrake and may thus perform the function of metal bending. As anotherexample, select stations may each be equipped with welding equipment andmay thus perform the function of welding. Still further, select stationsmay each be equipped with grinding tools and may thus perform thefunction of grinding. Various exemplary stations 102 and their functionswill be described in the examples set out in greater detail below.

The number of stations 102 and the assignment of each station 102 to aparticular function will be largely dependent upon factors such as themanufacturing environment and the types of parts, component partassemblies or products that are to be fabricated, manufactured,processed, assembled, etc., by the manufacturing cell 100. Further,factors such as the complexity of functions being performed by thevarious stations 102, the volume of work to be performed by themanufacturing cell 100, the space required by each station 102, thespace available for the manufacturing cell 100, the available resourcesincluding machines and necessary work implements and other like factorsmay be considered when determining the number and functions of thevarious stations 102 of a given implementation of a manufacturing cell100.

In the exemplary layout of the manufacturing cell 100, the variousstations 102 are arranged generally in two rows of stations 102 that areseparated by a main aisle passageway 104. A forklift truck 106 traversesthe main aisle passageway 104 in a manner that allows the forklift truck106 to service all of the stations 102 as will be described in greaterdetail herein so that only one forklift truck is required for operationof the entire manufacturing cell 100. The cell 100 further comprisesstorage units 108 which are accessible to the forklift truck 106. Forexample, storage units 108 may comprise vertically stacked racks locatedalong both sides of the main aisle passageway 104 that may extend ashigh as the forklift truck 106 can access. Alternatively, the height ofthe storage units 108 may be limited by the height of a building orother structure that houses the cell 100. If desired or needed,additional storage units 108 may be positioned outside and adjacent tothe main aisle passageway 104, e.g., in a row that intersects and isperpendicular to the main aisle passageway 104.

For example, as shown, the manufacturing cell 100 includes a first endportion 100A and a second end portion 100B, which are located at therespective ends of the rows of stations 102. The first end portion 100Amay include a first additional aisle passageway 104A that extendsgenerally perpendicularly to, and intersects a first end of the mainaisle passageway 104, e.g., for supporting additional storage units 108.Similarly, the second end portion 100B may include a second additionalaisle passageway 104B that extends generally perpendicularly to, andintersects a second end of the main aisle passageway 104, e.g., forsupporting additional storage units 108.

According to an aspect of the present invention, the forklift truck 106is equipped for guided steering, at least within the main aislepassageway 104. For example, a wire guidance system 107 (schematicallyrepresented by a line down the main aisle passageway 104 and within thefirst and second end portions 100A, 100B) may be utilized to facilitateoperation of the forklift truck 106 within the main aisle passageway 104and along the first and second end portions 100A, 100B, if provided inthe cell 100. The use of guided steering technologies, such as wireguidance or others, allows the overall dimensions of the aisle 104 to bescaled down significantly, thus reducing the overall size requirementsof the manufacturing cell 100. Guided steering also enables the stockhandler to concentrate on the many other aspects of efficientlyoperating the forklift truck 106 including traction and fork control(raising, lowering and properly orienting the forks to move containerswithin the cell 100).

The forklift truck 106 may comprise a TSP6000 turret stockpicker truckcommercially available from Crown Equipment Corporation of New BremenOhio, USA, the assignee of the present application. When the TSP6000truck is steered by an operator, aisle size is commonly at leastapproximately 108″ (2.74 meters) wide. However, guided steeringtechnology, such as a wire guidance system, enables the TSP6000 tooperate in an aisle, such as the main aisle passageway 104, having asignificantly reduced width such as 71″ (1.8 meters), which is justslightly greater than the width of the TSP6000 itself

In this regard, a Crown TSP6000 truck is particularly suitable for usein the manufacturing cell 100 as the TSP6000 has a fork carriage that isside shifted and rotated 180 degrees, allowing the truck to pickup anddeposit loads to the front or either side of the truck. Accordingly, themain aisle passageway 104 need not include extra width to accommodateturning or other maneuvers by the forklift truck 106. For example, theTSP6000 can traverse the main aisle passageway 104 forwards andbackwards along a path controlled by the guided steering system andcorresponding wire guidance system 107. Without changing the directionof its power unit, the TSP 6000 truck can raise, lower, turn and extendits forks to pickup and place loads to either side of the forklift truck106. Thus, containers can be picked up, placed and moved from thestorage units 108, including the storage units 108 along and on eitherside of the main aisle passageway 104 efficiently without requiring thestock handler to manually perform difficult maneuvers, such as may berequired with other forklift trucks.

The manufacturing cell 100 may also include additional ancillaryfeatures, such as the provision for a supervisor or team station 110,which may include an office, desk, computers and other managerialrelated tools. Also, the manufacturing cell 100 may include a truckdocking area 112, which provides a convenient location for batterycharging, maintenance, storage, etc., of the forklift truck 106 when theforklift truck 106 is not in service.

Exemplary Cell Configurations

For purposes of discussion herein, the stations 102 will be describedwith reference to the manufacture of component parts for materialshandling vehicles, and in particular, to the manufacture of doors andcovers for various models of forklift trucks. The doors and coversutilized on forklift trucks may comprise, for example, components orcomponent part assemblies of various sizes, shapes and configurationsthat are installed onto the corresponding trucks, e.g., using one ormore pins, bolts or other suitable coupling members. However, thisapplication is discussed herein by way of illustration and not by way oflimitation as to the configuration and/or application of themanufacturing cell 100.

In the manufacture of doors and covers for forklift trucks, threetypically required functions include bending, welding and grinding. Dueto factors including product line differences and correspondingmachinery and work implements required for those different productlines, time required to complete a job, and other relevant factors,there may be several stations 102 that perform the same function, suchas bending, welding, grinding and the like. Each station that canperform the same function may be assigned to produce components for asingle product line or may be assigned to produce components for two ormore product lines.

In the illustrative embodiment, the manufacturing cell 100 comprisesthree press brake stations 114, twelve welding stations 116 and twogrinding stations 118, which will each be described in greater detailherein. In practice, a cell 100 comprising any reasonable number ofstations 102 may be implemented. Moreover, the specific implementationof a manufacturing cell 100 will define the number of stations 102 andthe functions implemented by each station 102. As such, the variousaspects of the present invention are not limited to, nor require per se,press brake, welding and grinding stations.

For example, the concepts herein may also be applied to the manufactureof other parts or part assemblies, such as vehicle chassis, motors,transmissions, electrical systems, hydraulics systems, forks/mastsystems, and battery systems or other parts or parts assemblies, etc.Moreover, the concepts herein may be applied to manufacturing cellsutilized for applications other than component parts and component partassemblies of materials handling vehicles and can be applied tomanufacturing processes in general.

Each station 102 of the manufacturing cell 100 is equipped with thenecessary work implements, e.g., the tools, tooling, jigs, dies andmaterials, required to perform the function(s) assigned to that station102. For example, to facilitate utilization of the press brake stations114, the storage units 108 within and about, e.g., along the firstadditional aisle passageway 104A, may include dedicated brake holdingracks for holding tools, supplies, materials and other work relatedimplements needed to efficiently operate the corresponding press brakes.Similarly, the press brake stations 114 may include further dedicatedstorage units, e.g., die racks 120 to store the assigned dies that areutilized by the press brake at that press brake station 114.

To further enhance efficiency of operation, each storage unit 108 mayhave one or more dedicated storage positions. Moreover, each dedicatedstorage position may be dimensioned to correspond with an associatedcontainer that is used to hold stock as will be described in greaterdetail herein. For example, as shown in the manufacturing cell 100 inFIG. 1, storage units 108 may be provided for each station 102, arrangedgenerally adjacent to the aisle 104. This arrangement provides aconvenient layout for the forklift truck 106 to move containersthroughout the manufacturing cell 100 and to provide the appropriatecontainers to the associated stations 102.

With reference to FIG. 2, an exemplary storage unit 108 is illustrated,such as may be positioned to one side of the main aisle passageway 104.As illustrated, the storage unit 108 is positioned above a station-aisleinterface 122 which serves as a transition between the main aislepassageway 104 and a corresponding station 102. Two conveyors arepositioned so that an end portion of each conveyor is proximate to thecorresponding station-aisle interface 122. As such, the conveyors areaccessible to the forklift truck 106 from the main aisle passageway 104.However, other suitable arrangements may alternatively be utilized. Forexample, in practice, a station-aisle interface 122 can include an openarea that does not include conveyor(s) e.g., by providing a positionunderneath a storage unit 108 between a station 102 and the main aislepassageway 104 to store large containers 124 that would be impracticalfor use by the conveyors. As another example, different conveyorconfigurations may be provided in addition to or in lieu of that shownin FIG. 2. As another example, two adjacent stations 102 may share acommon conveyor. Thus, the station-aisle interface for two or morestations may be a single shared interface, or it may interface withcommon components, such as a common conveyor. Various station-aisleinterface configurations will be described in greater detail herein.

A plurality of rack shelves 123 are spaced vertically above thestation-aisle interface 122. Each rack shelf 123 supports one or morecontainers 124. In practice, any number of rack shelves 123 may be used,depending for example, upon the vertical height requirements ofcontainers 124 utilized in the storage unit 108, the available ceilingheight, the maximum lift height of the forklift truck 106 and the like.Any reasonable number of containers 124 may be positioned on each rackshelf 123. The specific application may affect the allocation of rackshelves 123 and/or containers 124 to the rack shelves 123.

Each container 124 may hold and store one or more items, including forexample, raw materials, parts, part assemblies, products, etc., that areused within and/or are fabricated, manufactured, processed, assembled,sub-assembled, etc., within the manufacturing cell 100. As shown, eachcontainer 124 includes a pair of fork receiving slots 125A, 125B, whichare dimensioned to correspond with the forks of the forklift truck 106.

According to an aspect of the present invention, at least some of thecontainers 124 comprise pallet style containers that are physicallysmaller than a conventional pallet, for example half the size of aconventional pallet. The use of smaller containers, for example half thesize of a conventional pallet, enables the overall physical size of themanufacturing cell 100 to be reduced. The actual realized space savingsof a smaller pallet sized container compared to a conventional palletsized container will depend upon the nature, e.g., size, quantity, etc.,of the stock items being stored on each container. In practice, anypractical number of container sizes may be implemented. Moreover, two ormore containers 124 may store units of the same type of stock.

According to an aspect of the present invention, a system is providedfor the organization and storage of containers 124 within themanufacturing cell 100. To enhance efficiency of operation, eachcontainer 124 is provided with a container tag 126. The container tag126 may be temporarily fixed to the corresponding container 124. In aworking embodiment of the present invention, tags formed on a magneticmaterial were used. However, other securing arrangements can be used.The container tag 126 may provide relevant instructions and information,such as an identification of the corresponding container 124, theexpected container contents, an address/location of where within themanufacturing cell 100 the associated container 124 should be stored(such as by specifying a designated storage unit 108 and optionally, aspecific position within a given storage unit 108), the startingquantity of stock items on the corresponding container 124, where toreplenish the container contents from when the container has beenemptied, what component parts are required to replenish each item on thecorresponding container 124 and/or any other desired information.

Correspondingly, each storage unit 108 may have one or more dedicatedstorage positions, which may be identified using a suitable tag. Thetags applied to the storage units 108 may also identify the expectedcontent of a container stored at the corresponding storage position. Theapplication of dedicated storage positions within storage units 108allows, for example, each storage position to be dimensioned tocorrespond with an associated container 124.

For example, rack tags 127 may be provided at the face, e.g., on thevertical side surface of the rack shelves 123 or other suitable locationof the storage unit 108. The rack tags 127 may include any suitableinformation, including for example, a corresponding identifier of thestock expected to be stored at that location. This identifier may beused, for example, to identify a location for storing a container 124.

One or more additional rack tags 128 may also be provided, e.g., todesignate further information in addition to or in lieu of the rack tags127. For example, the additional rack tags 128 may be utilized toidentify a specific location within an associated storage unit 108. Theinformation provided on the container tags 126 and rack tags 127, 128can take various forms including any combination of information encodedinto a sensed or scanned technology, e.g., scannable bar codes, RadioFrequency Identification Tags (RFID), etc., alphanumeric, symbols, iconsand other visual human readable or machine readable indicia. Using theinformation on a given container tag 126 and a corresponding rack tag(s)127,128, the stock handler operating the forklift truck 106 has animmediate visual indication that can be used to verify that a givencontainer 124 is in an appropriate storage location by matching stockpart identification on both the storage tag 126 and the rack tag 127 andby matching the storage address of an associated container 124 on boththe container tag 126 and the rack tag 128. Other arrangements andinformation may alternatively be utilized for the rack tags 127, 128. Inthis regard, the dedicated storage positions may be reassignable toaccommodate changes in the flow of work through the manufacturing cell100, such as by changing or replacing the rack tags 127, 128.

As an alternative arrangement, the locations within storage unit 108 maybe assignable, e.g., by the stock handler operating the forklift truck106. For example, each storage unit 108 may provide a plurality ofstorage positions that can be allocated by the stock handler orotherwise. In this regard, the stock handler operating the forklifttruck 106 may chose any available location within the associated storageunit 108 to position or put away an associated container 124. The stockhandler further associates, e.g., via an electronic record or manualrecording, the container 124 to its newly assigned location.

The storage unit 108 may be used to store containers 124 that eachsupport quantities of one or more internal stock items, i.e., parts,hardware, components, component assemblies and the like necessary foroperation of the corresponding station 102. Where appropriate to anunderstanding of the various aspects of the present invention, thecontainers 124 reserved for use within the manufacturing cell 100, i.e.,that support “internal” stock items will be further designated as cellcontainers 124A. The storage unit 108 may also be used to storecontainers 124 that supports product produced within the cell 100 thatflows out of the cell 100, e.g., to a downstream process, to a customer,etc. Such product is placed on a container 124 that will be transportedout of the manufacturing cell 100. Where appropriate to an understandingof the various aspects of the present invention, the containers 124 thatare to be transported out of the manufacturing cell 100 will be furtherdesignated as transport containers 124B.

The transport containers 124B can be distinguished from cell containers124A in a number of ways, such as by making the transport containers124B different colors than cell containers 124A. The transportcontainers 124B can be further distinguished from one another alongproduct lines, i.e., based on the products that are to be built usingthe parts on the transport containers. Thus, transport containers 124Bfor a given product may all be colored the same color. In this way, itis unlikely that parts for one product will be delivered to a productionline that produces a different product.

In practice, the above idealized organization need not be strictlyadhered to. For example, under certain circumstances, the vertical spaceor width of a given storage unit 108 may not allow all containers 124that flow into and out of the associated station 102 to be positionedalong the main aisle passageway 104 adjacent to, e.g., above thestation-aisle interface 122.

As an example, assume the stock handler receives an order for themanufacture of one or more instances of part A, where each instance ofpart A requires components B, C and D to be welded together according toa prescribed arrangement. Further, assume that components B, C and D arestored on respective cell containers 124A in a storage unit 108associated with a corresponding welding station 116 to which the orderhas been assigned (such as the storage unit 108 illustrated in FIG. 2).The stock handler travels down the main aisle passageway 104 to theappropriate storage unit 108 and utilizes the forklift truck 106 toretrieve the required cell containers 124A that support components B, Cand D, respectively. The retrieved cell containers 124A are delivered tothe station-aisle interface 122 of the corresponding welding station116, e.g., by positioning the cell containers 124A containing componentsB, C and D onto one of the illustrated conveyors. The stock handler mayalso utilize the forklift truck 106 to provide a transport container124B that is to be used for one or more completed instances of part A tothe station-aisle interface 122 of the corresponding welding station116.

When the appropriate cell containers 124A and optionally, a transportcontainer 124B, are loaded into the station-aisle interface 122, thestation operator performs the appropriate work to manufacture the numberof instances of part A required by a given order and each instance ofthe manufactured part A is placed on the transport container 124B. Thestation operator then returns the cell containers 124A corresponding tocomponents B, C and D as well as the transport container 124B to thestation-aisle interface 122. The stock handler then typically puts thecell containers 124A back to a suitable storage location, e.g., in thestorage unit 108 from where they came. Moreover, the stock handlertypically relocates the transport container 124B to a different station,e.g., a grinding station 118, or the transport container 124B can berelocated to an outbound staging area for removal of the transportcontainer 124B from the manufacturing cell 100.

Each of the cell containers 124A for components B, C and D may hold aquantity of components that is greater than what is required tomanufacture part(s) A. As such, if there are components still remainingon a given cell container 124A when it is returned to the station-aisleinterface 122, the stock handler simply restores that cell container124A to its corresponding storage location using the forklift truck 106.If a cell container 124A is returned from a station 102 empty, the stockhandler delivers the cell container 124A to an appropriate location anda replenishment operation is triggered as will be described in greaterdetail herein. As noted above, the location and/or other instructionsfor replenishment may be provided on a container tag 126 of acorresponding emptied cell container 124A thus facilitating an immediateand intuitive response from the stock handler.

In an exemplary implementation, if a cell container 124A requirescomponents from outside the manufacturing cell 100 for replenishment,e.g., new blanks for a door or cover, an order may be manually orelectronically generated. To that end, the stock handler may remove thecontainer tag 126 from the corresponding cell container 124A, place theempty, untagged container in a container recycle area and scan orotherwise record that the cell container 124A previously identified bythe tag 126 is empty. Upon scanning the container tag 126, an order maybe automatically generated and communicated to a work area outside themanufacturing cell 100 to provide the needed components to the cell 100,e.g., by performing laser cutting, drilling or other pre-cell activity.As will be described in greater detail below, the stock handler may thenrelocate the container tag 126 to a suitable location, such as a tagboard, and the recycled container 124 can then be transported outside ofthe cell 100 for use elsewhere in the factory, for example to returnneeded components to the cell 100, or for reuse within the cell 100.

According to an aspect of the present invention, there may be two ormore cell containers 124A that contain the same component type. In thisregard, it may be of interest to deplete a first one of the cellcontainers 124A before using remainder one of the cell containers 124A.As such, a flag, such as may be provided in the form of additionalindicia, a tag, clip, color, label or other indicator may be used todesignate to the stock handler, which of like cell containers 124A touse first.

The above-simplified example is presented by way of illustration and notby way of limitation as to an operation that may be performed using themanufacturing cell 100. As noted, not all containers 124 at a givenstorage location 108 may be required for a given work order. Moreover,each cell container 124A may store a quantity of internal stock items inexcess of what is required to satisfy a given work order. In thatinstance, the cell containers 124A may be simply returned to theirstorage location, which may conveniently be located right at thestation-aisle interface 122.

When determining the quantity of internal stock items to store withinthe manufacturing cell 100, any number of techniques may be utilized.For example, a manager, supervisor, analyst, etc., can evaluate dailydemand, standard deviation, replenishment cycle, factor in tolerances,seasonal, periodic, outlier and other factors to determine the number ofcontainers and the quantity of internal stock items per container whenestablishing a particular implementation of the manufacturing cell 100.

Referring to FIG. 3, a simplified schematic illustration of themanufacturing cell 100 is shown. As is further illustrated, an indicator130 is associated with at least some of the stations 102. The indicators130 provide a status of the associated station 102, and may beimplemented using any suitable techniques. Moreover, while illustratedfor purposes of convenience and clarity as being positioned adjacent tothe storage units 108 proximate to the main aisle passageway 104, otheralternative locations for the indicators 130 may be implemented. Stillfurther, the indicators 130 may be positioned in different locationsdepending, for example, upon the implementation of the correspondingstation 102.

According to an aspect of the present invention, the indicators 130provide a visual indication that identifies one of several possiblestates of the corresponding station 102. For example, the visualindicator 130 may identify the station as shut down, in need of thestock handler operating the truck 106, or full and/or running. Thevarious states may be represented by pictures, numbers, icons or othersuitable indicia. Further, the various states of each indicator 130 maybe identified based upon color.

As an example, each indicator 130 may utilize a light that is red toindicate that the corresponding station 102 is in need of immediateassistance, a light that is yellow to indicate that the correspondingstation 102 is in need of the stock handler, and a light that is greento indicate that the corresponding station 102 is operating. In anexemplary implementation, when the stock handler delivers at least onecontainer 124 relating to work to be completed to a station 102, e.g.,by placing one or more containers 124 at the station-aisle interface122, the station operator at the station 102 sets the indicator 130 to afirst color, e.g., green to indicate that the station 102 is running Forexample, as illustrated in FIG. 3, most of the indicators 130 are asolid color, indicating the first state.

When the work is complete and one or more containers 124 are ready toflow out of a given station 102, e.g., by positioning the containers 124at the corresponding station-aisle interface 122, or where the stationoperator at a corresponding station 102 is waiting for containers 124 tobe received at the station 102, the indicator is toggled to a secondcolor, e.g., yellow. For example, as shown in FIG. 3, the indicator 130in the upper right side of the figure has different shading compared tothe indicators 130 directly there-below to distinguish the second statefrom the first state. Still further, if service from the stock handleris needed immediately, the station operator can toggle the correspondingindicator 130 to a third color, such as red. For example, as shown inthe fourth station 102 down from the top left of FIG. 3 adjacent to theforks of the lift truck 106, the indicator 130 has yet a differentshading indicating the third state.

Given the above system, the station operator at each station 102 has thecapability of controlling the state of his/her station 102. Moreover, asupervisor, manager or other person can stand at one end of the mainaisle passageway 104 and with a quick visual check, determine the stateof the entire manufacturing cell 100 by noting the red, yellow and greenlights. Accordingly, the state of the manufacturing cell 100 can besimply and quickly determined. Still further, the activity of the stockhandler operating the guided forklift truck 106 can be directed by thestate of the indicators 130. For example, the stock handler may haveshop orders, either in hardcopy or softcopy, which tells the stockhandler the jobs that need to be completed, the quantity and location ofrequired internal stock items, etc. The stock handler directs theworkflow related to delivery of the containers 124 into the stations102, e.g., based upon the shop orders. Moreover, the stock handlerdirects the removal of the containers 124 from the stations 102 basedupon the status of the stations 102 as designated by the indicators 130.As such, the tasks required by the stock handler may be organized and/orsequenced in response to yellow lights and/or red lights, etc.

Different and/or additional states may alternatively be designated.Further, other means of conveying the states of each indicator 130 mayalternatively be utilized. For example, each indicator 130 may utilizevisual and/or audible cues as to the current state. Moreover, theindicators 130 may be tied or linked into a computer system, such as formonitoring workflow, for controlling inventory, for verifying and/oridentifying work orders, etc.

According to an aspect of the present invention, a Kanban type systemmay be utilized to conceptually organize the manufacturing cell 100. Asan example, for manufacturing relatively large parts such as doors andcovers for materials handling vehicles, each Kanban may comprise apallet, ½ sized pallet, skid or other form of container that can betransported by the forklift truck 106. Each Kanban (also referred toherein generally as a container 124, a cell container 124A and/or atransport container 124B) may be utilized to store one or more likeparts, component or component assemblies, materials, etc. required forprocessing within the manufacturing cell 100.

In general, a Kanban system strives to align inventory levels withactual consumption by utilizing a signal to trigger the various stations102 of the manufacturing cell 100 to produce particular parts/partassemblies based upon a downstream manufacturing need for the part/partassembly. Methods of utilizing the manufacturing cell 100 are describedin greater detail herein. Moreover, strict adherence to a formal Kanbansystem is not necessary to exploit the capabilities of the manufacturingcell 100.

With reference to FIG. 4, the illustrated manufacturing cell 100includes a plurality of conveyor devices 132. As shown, there are twoconveyor device 132 associated with each station 102 except for the twogrinding stations 118 which share a single conveyor device 132G betweenthem. For stations 102 having two conveyor devices, the operators mayactively work from a first container 124 or group of containers 124transported to the work area of the station on one of the conveyordevices 132 while a second container 124 or group of containers 124 isstaged or queued on the other one of the conveyor devices in a mannerthat minimizes work interruptions. The multiple conveyor approach alsoprovides flexibility in the implementing strategies such as first-in,first-out (FIFO) processing at the station 102.

As an illustrative example, a station 102, such as a press brake station114, may receive one or more containers 124 at a correspondingstation-aisle interface 122 by having the set of containers placed bythe forklift truck 106 on a first one of two conveyor devices 132. Theoperator at the press brake station 114 performs the required bendingoperations and returns the completed parts back to an associatedcontainer 124. Upon completing the assigned task, a station operatorrelocates the container(s) onto the other one of the conveyor devices132 for transport back to the station-aisle interface 122. The stockhandler then utilizes the forklift truck 106 to pick up the container(s)124 from the second one of the conveyor devices 132 at the station-aisleinterface 122 to be delivered to another station 102 within themanufacturing cell 100 or to be delivered to another suitable locationfor transport outside the cell 100. As such, in this arrangement, afirst one of the conveyor devices 132 is used for “inbound” containers124 to the station and the other conveyor device 132 is used for“outbound” containers 124 from the station.

Alternatively, each of the conveyor devices 132 may be used as bothinbound and outbound devices, that is, to both receive and returncontainers 124 between the station 102 and corresponding station-aisleinterface 122. As an illustrative example, a station 102, such as awelding station 116, may receive one or more containers 124 at acorresponding station-aisle interface 122 by having the set ofcontainers placed by the forklift truck 106 on a first one of twoconveyor devices 132. A second set of containers may be staged by thestock handler operating the forklift truck 106 on the second conveyordevice 132. Thus, the operator of the welding station 116 can performthe necessary work on the contents of the first set of containers 124 onthe first conveyor device 132. Upon completion of the task, the firstset of containers 124 can be returned to the station-aisle interface 122to be picked up by the stock handler operating the forklift truck 106.The station operator can then move to the second conveyor device 132 toperform the necessary work on the contents of the second set ofcontainers 124. While the station operator is performing the intendedtask, the stock handler can pick up and put away the first set ofcontainers 124 and stage a third set of containers 124 on the firstconveyor device 132 to queue up the next job for the station operator,and this pattern of operation may be repeated as necessary.

As shown in FIG. 4, the two grinding stations 118 share only a singleconveyor device 132G. In the exemplary implementation of themanufacturing cell 100, the grinding stations 118 are an optional laststation in the flow through the manufacturing cell 100. As such, thesingle conveyor device 132G is used as an inbound conveyor to both ofthe grinding stations 118. The operator in each grinding station 118performs grinding operations on the next item that comes in on theshared conveyor 132G. When grinding operations are complete, thecorresponding transport containers 124B are staged to be removed fromthe manufacturing cell 100 as will be described in greater detail below.In this configuration, the station-aisle interface for each of thegrinding stations 118 may comprise the shared conveyor 132G.

If the manufacturing cell 100 is implemented in a Kanban or other “pull”type environment, the emptying of a container 124, regardless of whetherthat container is a cell container 124A or a transport container 124B,may signal that a replenishment operation is required. As such, anaction such as scanning the container tag on an emptied container 124may automatically trigger a replenishment workflow. By triggeringworkflow automatically, the manufacturing cell 100 can more quicklyrespond to observed demand, such as by propagating a demand or othersuitable inventory signal or signals through the manufacturing chain.

The Kanban system as described herein, e.g., for the manufacture ofdoors, covers or other components of a finished product, e.g., amaterials handling vehicle, can be integrated with “push” systems and/oralternative implementations of “pull” systems so that the Kanban is onlyoperated with respect to the manufacturing cell 100 as described ingreater detail herein. That is, the Kanban system implemented within themanufacturing cell 100 may be integrated with traditional push orforecast systems, traditional “pull” systems or with systems thatutilize a hybrid approach where some aspects of manufacture are at leastprimarily push driven while other aspects are at least primarily pulldriven.

With reference to FIGS. 1-4, as noted in greater detail above, themanufacturing cell 100 may include a plurality of stations 102. Certainstations may be assigned to the same general function but performdifferent operations, e.g., manufacture parts associated with adifferent product line or product lines. For example, as shown, thereare three press brake stations 114. Each press brake station 114 may beequipped with its own unique set of dies, e.g., as stored on thecorresponding die racks 120, which may correspond to a particular size,style, configuration, etc. of door. As such, in order to changemanufacturing, for example, from a first door type to a second doortype, the system need only route the appropriate container 124 to thecorresponding one of the press brake stations 114. The operator at theassigned press brake station 114 already has the appropriate tools, diesetc., to make the desired part, so there is minimal to no waste in laborrelated to the preparation before commencing actual work.

As another example, two or more of the stations 102 may be assigned tothe same general operation for work associated with the same productlines. For example, there may be several welding stations 116 that areeach equipped with their own instance of the required work implements,e.g., jigs associated with each supported product line. As such, astation operator at a given one of the welding stations can quickly setup for a new one of the supported product lines because the requiredwork implements are stored at the station 102. The grinding stations 118may also each be similarly equipped so that work requiring a grindingoperation can be performed at either grinding station 118.

Accordingly, aspects of the present invention reduce variation andprocess adjusting because the individual stations 102 position workimplements, e.g., fixtures, jigs, supplies and tools, at the point ofuse. Accordingly, this may allow an operation to meet maximum capacitydemands and/or enable condensation of station operator operating shifts,e.g., to reduce/consolidate a workforce from three or two shifts down totwo or one shift so that all station operators in the manufacturing cell100 can work more desirable hours. Being able to offer appealing workinghours may mitigate resource problems, such as where it may be difficultto obtain skilled employees to work late, or otherwise undesirablehours.

PRESS BRAKE STATIONS

The press brake stations 114 may be utilized to bend or otherwisemanipulate the heavy gauge working materials, e.g., to form parts usedto make the doors and covers. In press-brake bending, a workpiece istypically placed between upper and lower dies. The desired part isformed through force and pressure exerted on a workpiece by moving a ramtowards a corresponding bed. The upper and lower dies define the bends,folds, etc., which the ram imprints on the workpiece. As such, thecorrect die must be utilized for each product manufactured by themanufacturing cell 100.

The dies utilized in the formation of parts used as or to constructdoors, covers, etc., for each product line may be divided among, andlocally stored at corresponding press brake stations 114 so that productchangeover may be implemented relatively expediently. For example,changeover may simply require selecting an appropriate one of thebraking stations 114. Alternatively, where a selected brake station 114must perform a changeover, e.g., to accommodate a run of a new productline, all of the necessary work implements are stored right at the brakestation 114.

Other tooling, such as may be required for punching, countersinking,dimpling, embossing operations, etc., may also be stored at theappropriate press brake stations 114. Still further, the press brakestations 114 may also include other ancillary equipment, such as gaugingequipment, soapsticks and other tools for manipulating stock to formdoors and covers for materials handling vehicles.

Moreover, the press brake stations 114 need not be limited to operationsrelated to doors and covers. Rather, with proper dies and toolingconfiguration, the press brake stations 114 may be utilized for themanufacture of other components of materials handling vehicles (or otherproducts in general). Further, the illustrated press brake stations 114are set up to bend or otherwise manipulate heavy-gauge materials.However, depending upon the application of the manufacturing cell 100and/or parts not related to the application but required by themanufacturing facility including the cell 100, the press brake stations114 may be equipped to perform light gauge processing, e.g., usingmanual or automatic folding equipment like bending machines and/orswivel benders, pan, leaf or box brakes, folders, etc.

In keeping with the exemplary Kanban system discussed above, the brakestations 114 may also include parts or blanks used in the press brakes,such as by storing suitable raw materials in the storage units 108associated with the corresponding brake stations 114. As an example,when raw material is taken from a container 124 stored in a storage unit108 associated with one of the brake stations 114, the transitioning ofthe container 124 may trigger a replenishment operation or gatingoperation, where replenishment parts are cut from stock materials, suchas by using shears, lasers, saws, etc. The cutting may be performed by aprocess outside of the manufacturing cell 100, or by a process internalto the manufacturing cell 100.

Referring to FIG. 5, each press brake station 114 may include, forexample, a different type of press brake 136A, 136B, 136C to provideflexibility to the manufacturing capabilities of the manufacturing cell100. According to an aspect of the present invention, each press brakestation 114 may also include an inbound conveyor 132A, an outboundconveyor 132B and a cross conveyor 132C. The inbound conveyor 132A andthe outbound conveyor 132B are generally long, conveyance devices tomove containers 124, e.g., from the corresponding station-aisleinterface 122 to the work area of the corresponding press brake station114, and may be implemented, for example using a roller-type conveyorsystem. The cross conveyor 132C may comprise, for example, a roller balltransfer platform that bridges the inbound conveyor 132A to the outboundconveyor 132B so that containers 124 can be moved easily from theinbound conveyor 132A to the outbound conveyor 132B. Moreover, there maybe a location near the cross conveyor 132C of the press brake stations114, e.g., at point 132D, where an operator can discard an emptycontainer 124 which is not returned to the station-aisle interface 122.

As shown, the workflow, and thus the location of the inbound conveyor132A compared to the location of the outbound conveyor 132B is selectedin accordance with the working direction (left to right or right toleft) of the corresponding press brake. Accordingly, for purposes ofillustration, the workflow, and correspondingly the order of the inboundconveyor 132A relative to the outbound conveyor 132B is opposite for thepress brake station 114 associated with the first press brake 136Acompared to the second and third press brake stations 114 correspondingto press brakes 136B and 136C respectively.

Also, as illustrated in FIG. 5, the cross conveyor 132C that isassociated with the first press brake 136A is implemented as twosections, including a first section 132C-1 and 132C-2. In this exemplaryimplementation, the first press brake 136A may be a 230 ton press brakecapable of manipulating relatively large parts. As such, the firstsection 132C-1 of the cross conveyor 132C may be height adjustable toaccommodate the movement of parts from their associated container 124 tothe press brake 136A and back to the container 124. An exemplaryadjustable height table suitable for use as the first section 132C-1 ofthe cross conveyor 132C is described and illustrated with respect toFIG. 13B herein.

The roller balls 133 of the cross conveyors 132C may comprise, forexample, large steel ball bearings or other structures that reduce theforce required to slide components across the corresponding crossconveyor 132C. In practice, the number of roller balls 133, the spacingbetween the roller balls 133, the size of each roller ball 133, etc.,will likely depend upon the specific implementation. Also, otherconfigurations of conveyor devices 132A, 132B, 132C may be implemented.

The disclosed combination of roller-type conveyor for the inboundconveyor 132A and outbound conveyor 132B in combination with the rollerball type conveyor for the cross conveyor 132C may be selected andmaintained, for example, to limit the amount of force required to pushor pull items over the conveyors to facilitate the manufacture ofheavier parts with reduced exertion on the part of the press brakestation operators and assistants if needed.

In an exemplary implementation of making doors and covers for materialshandling vehicles, flat blanks may be pulled from stock by the stockhandler operating the truck 106. The stock handler places one or moreflat blanks supported on a container 124, on the inbound conveyor 132Aof an appropriately assigned press brake station 114. The stock handlermay also leave an empty container 124 that is to be filled and returnedto a welding area (cell container 124A) or to a location outside thecell (transport container 124B). Parts are formed at the brake pressstations 114, e.g., in a first-in, first-out (FIFO) manner Afterforming, the parts are sent to the corresponding station-aisle interface122 on the outbound conveyor 132B for pickup by the stock handleroperating the forklift truck 106. The container 124 that held the blanksmay be returned on the outbound container 132B or can be discarded, forexample at the designated discard area 132D.

The stock handler then delivers the parts in their correspondingcontainer 124 from the press brake station 114 to a dedicated locationwithin a correspondingly assigned weld area, e.g., to an inboundconveyor of a welding station 116 or to a suitable storage unit 108located adjacent to a correspondingly assigned welding station 116.Alternatively, the container 124 may be relocated to a storage area forpickup and delivery to a location outside the manufacturing cell 100,such as where no further processing is required by stations 102 withinthe manufacturing cell 100.

When the stock handler picks up the container 124 having formed partsthereon, a replenishment order for new blanks may automatically begenerated, such as when an appropriate tag is scanned, etc.Alternatively, the replenishment order may be triggered when the partsare used up, e.g., removed from their associated container 124 in adownstream process, which may occur outside the manufacturing cell 100.For example, the formed parts may need to pass to a welding station 116and to a grinding station 118 before being removed from themanufacturing cell 100. The parts may then go downstream, such as to apaint process which is outside the cell 100. However, the parts willremain on the same container for all of the above processing and thusnot trigger a replenishment operation. A replenishment order is createdwith the parts are removed from their container, such as in an assemblyprocess where the covers are assembled to corresponding materialshandling vehicles.

Where the containers 124 and/or parts to be handled are too large to bemanually maneuvered by a station operator, a mechanical manipulator 140or other assistance device or devices may be utilized. The manipulator140 may be an overhead crane or other apparatus utilizing hooks orhandling devices operated using suction, pressure, etc. to assist inlifting and handling large, bulky, awkward parts. For example, themanipulator 140 may assist the operator in moving heavy parts, e.g., inexcess of 45 pounds (20.41 kilograms) or some other reasonable weight.An exemplary manipulator 140 is described with reference to FIG. 15.

With reference to FIG. 6, when operating a large press brake, it is notuncommon for a required die to weigh several hundred pounds to over athousand pounds. The weight of the die may be a limiting factor in thetime required for a station changeover. However, according to an aspectof the present invention, a work implement assist is provided to help anoperator move such heavy objects. In the illustrative example, the workimplement assist is utilized when changing out press brake dies and thusincludes a cradle 143 for receiving a corresponding die 144, as well asa lift assist block 145, which is positioned under the cradle 143. Thelift assist block 145 includes a block connector 146, such as anordinary quick connect pneumatic fitting for receiving air pressure. Airflows through the block connector 146, through ductwork (not shown)internal to the lift assist block 145 and flows out a plurality of holes(not shown) along the bottom surface of the lift assist block 145 thusproviding enough lift to “float” the cradle 143 and hence the die 145.Thus, when air pressure is applied to the block connector 146, the liftassist block 145 lifts up from the table or other surface enough that anoperator can easily and controllably navigate the die to an appropriateloading position within a corresponding press brake. For example, 20pounds per square inch (p.s.i.) to 40 p.s.i. may be sufficient to liftdies or other heavy work implements by an amount sufficient to allow asingle operator to move the die.

With reference to FIG. 7, several exemplary dies 144, each supported byan associated cradle 143 are shown. During a work changeover, a pressbrake operator may be required to change out the currently loaded die144 from the press brake. As noted above, the dies commonly weighseveral hundred pounds to over a thousand pounds. Accordingly, theoperator may first couple a source connect 147, such as a pneumaticquick connect fitting that mates with the block connector 146, to theempty cradle 143 that is associated with the currently loaded die 144.The source connect 147 is coupled to a source of pressurized air, suchas an air compressor by a suitable hose 148. As shown, the hose 148 isprovided on a take-up reel that automatically winds up the hose 148 whennot in use for convenient storage and to keep the hose 148 neatlystowed. When air pressure is applied through the hose 148, the liftassist block 145 of the empty cradle 143 provides lift that allows theoperator to easily, e.g., with one hand and minimal effort, navigate theempty cradle 143 along the table 149 to the press brake. When the die isremoved, the cradle 143 with the loaded die 144 thereon is floated backto its appropriate storage location.

Once the previous die 144 has been removed from the press brake and hasbeen returned to an appropriate storage location, the next die 144 isfloated into position for loading into the press brake in a manner asdescribed above. As shown, for purposes of convenience, the dies 144 arestored on a table 149 that generally forms an “L” shape with the pressbrake. As such, the dies 144 can be floated down the table and directlyinto a channel of the press brake where the dies 144 are to be loadedand removed from the press brake.

In order to provide efficient operation, the table 149 should be as flatand level as possible. Moreover, the height of the table should beadjusted to correspond with the height of the channel of the press brakewhere the dies are loaded and removed.

To enable a larger variety of part numbers to be produced in the pressbrakes, a quick die change procedure may be utilized, where anadditional person, designated as a production tender, will assist theprimary press station operator during die changeover operations. Theproduction tender is to have all tooling and gauging required to run thenext job assembled and ready to install before the changeover operationis to take place. During changeover, standard operations may be assignedto the primary operator and to the production tender.

As an example, to make a cover or door for a materials handling vehicle,blanks may be provided to the manufacturing cell 100. In this regard,the mechanism that directs the manufacturing to begin may be driven by apull or other demand based system based upon a forecast system, by amaterial requirements planning (MRP) system or otherinventory/manufacturing requirements process. The operator at anassigned press brake station 114 receives the blanks, which aredelivered, for example, by the stock handler on the forklift truck 106on an associated container 124. Based upon the parts to be fashioned, ifnecessary, the operator sets up the appropriate dies, which may bestored locally at the corresponding press brake station 114, e.g., in acorresponding die rack 120, 149.

When a cell container 124A containing blanks is emptied at one of thebrake presses 136A, 136B, 136C, e.g., when a container 124A is discardedat the designated area 132D, the corresponding part number may bescanned or otherwise identified, such as by scanning a tag or label onthe discarded cell container 124A, and an order may be sent to anassociated gating operation such as a laser cutter, etc. to replenishthe blanks. The above order to an operation outside of the manufacturingcell 100 may not be required, however. For example, a replenishmentorder may not be required where replacement blanks are already stored,e.g., within a storage area 108 within the manufacturing cell 100. Whereutilized, information may also be updated and/or entered into anassociated MRP or other electronic control and/or tracking system.

Alternatively, the order sent to the gating operation for replenishmentof the blanks may be triggered by a process downstream of themanufacturing cell 100. In this regard, a downstream process thatempties an associated transport container 124B that contains the doorsor panels may trigger the order, which may be communicated directly tothe gating operation. As such, the manufacturing cell 100 is notrequired to participate in the driving mechanism that triggersreplenishment of blanks to be delivered to the manufacturing cell 100.

Additionally, routing text provided in the order may identify, forexample, what type of container 124 must be used to return the part tothe manufacturing cell 100. The containers 124 are thus used as inputsto the MRP system since the equipment used in the gating system may notbe dedicated to the manufacturing cell 100 but may rather be used forother manufacturing operations within the manufacturing plant.

Alternatively, the gating system could be dedicated to the manufacturingcell 100 and may thus be driven directly by the Kanbans generated by themanufacturing cell 100. Still further alternative techniques may beutilized to track the flow of components through the manufacturing cell100.

As another example, blanks may be stored in a suitable storage location108 within the manufacturing cell 100. Under this alternativearrangement, as transport containers 124B are emptied in the plant thatactually manufactures various materials handling vehicles from thedoors, covers and other parts produced by the manufacturing cell 100,bar codes or other suitable designation indicia, tags or otherinformation bearing media may be read to create orders, such as forreplenishment of the used doors, covers and/or other parts. The ordersmay be transferred to and printed out on a suitable processing device,e.g., a desktop printer within the supervisor or team station 110 withinthe manufacturing cell 100. As yet another example, orders may becommunicated wirelessly, directly to the forklift truck 106. The stockhandler may utilize a printer on board the forklift truck 106, or thestock handler may process the orders electronically.

WELDING STATIONS

The manufacturing cell 100 as illustrated includes a plurality ofwelding areas. For example, as discussed above, the manufacturing cell100 includes twelve welding stations 116. In general, after parts forthe doors and covers have been processed at a press brake station 114,they are routed to an assigned welding station 116 where necessarywelding operations are performed to combine the parts to make therequired doors and covers.

As another example, the emptying of the containers 124 at the weldareas, e.g., at the welding stations 116, may be utilized to generateorders for the press brake stations 114 to produce more parts, thusdriving the “pull” of the Kanban philosophy.

According to an aspect of the present invention, the conveyor devices132 in each welding station 116 may be implemented as “seesaw” conveyors150, with the ends of the seesaw conveyors 150 moving in oppositedirections about a pivot point for the conveyors 150, i.e., as one endgoes downward the other end goes upward and vise versa.

Referring to FIG. 8, each seesaw conveyor 150 can be tilted so that itslopes downward toward the corresponding welding station 116 relative toa corresponding station-aisle interface 122 for an inbound orientationso that containers 124 travel into the corresponding welding station116. For example, the seesaw conveyor 150 may comprise a tiltableconveyor platform 152, e.g., a roller platform that has one end coupledto the end of a lift mechanism 154. As the lift mechanism 154 isoperated to move the corresponding end of the tiltable conveyor platform152 downward, the other end of the conveyor platform 152 proximate tothe station-aisle interface 122 moves upward so that containers 124 aregravity fed to a work area of the corresponding welding station 116.

Referring to FIG. 9, when an order is completed, the seesaw conveyor 150may be tilted in the opposite direction. For example, the lift mechanism154 may be extended upward so that the end of the conveyor platform 152proximate to the corresponding station-aisle interface 122 is moveddownward and the end of the conveyor platform 152 coupled to the liftmechanism 154 is moved upward. Accordingly, the seesaw conveyor is movedto an outbound orientation to enable containers 124 to be gravity fed tothe station-aisle interface 122 to be picked up by the stock handleroperating the forklift truck 106. The stock handler may then utilize theforklift truck 106 to take the container(s) 124 from the outboundoriented conveyor 150 to a suitable location. Thus, cell container(s)124A are taken to the next station 102 in the manufacturing cell 100 forfurther processing, such as to a grind booth in one of the grindstations 118 and transport container(s) 124B are taken to a completedoutbound conveyor of the manufacturing cell 100.

Each seesaw conveyor 150 includes a pivot point located at a positionalong the length of the tiltable conveyor platform 152. In practice, thepivot point may be positioned anywhere between the ends of the conveyorplatform 152. For example, offsetting the tilt position from thelongitudinal center of the conveyor platform 152 may provide improvedoperation depending upon factors such as the anticipated weight on theconveyor platform 152 and the lifting capabilities of the hydraulic liftmechanism 154. With regard to the work required of the hydraulic liftmechanism 154, the closer the pivot point is located to thestation-aisle interface, the less the work required. Also, by utilizinga seesaw configuration, the vertical distance that the conveyor platform152 must be raised and lowered by the lift mechanism 154 in order togravity feed containers 124 can be reduced relative to fixing one end ofthe conveyor platform 152.

Referring to FIG. 10, an exemplary system for controlling a seesawconveyor 150 is illustrated. The conveyor platform 152 has a first endportion 160 that includes a lift support 162 secured thereto. In theexemplary implementation, the first end portion 160 comprises the end ofthe conveyor 150 that is oriented in the work area of the correspondingwelding station 116 opposite of the end of the conveyor 150 that ispositioned at the corresponding station-aisle interface 122. As shown,the lift support 162 includes a first support 164 that extendshorizontally across the width of the conveyor platform 152 to form abase, a second support 166 that extends vertically from the firstsupport 164, and two angularly extending supports 168A 168B that eachform a right triangle with the first support 164 and second support 166.

To provide the tilt capability to the seesaw conveyor 150, the liftsupport 162 is coupled to the lift mechanism 154, which may beimplemented, for example, by a hydraulic cylinder 170. The hydrauliccylinder 170 includes a lower portion that is secured to a base 172 in amanner that allows the hydraulic cylinder 170 to pivot slightly as theend of the conveyor platform 152 is raised and lowered, such as by usinga pin, clevis or other suitable connection. The hydraulic cylinder 170is controlled to extend and retract a piston 174 having an end portionthat is coupled to the lift support 162, e.g., using a clevis or othersuitable connection. For example, as schematically illustrated, asupport positioned proximate to the apex of the lift support 162 may bereceived between the arms of a clevis, which is coupled to the end ofthe lift arm 174. A pin or other suitable arrangement may be used tosecure the support to the clevis.

Adjacent to the seesaw conveyor 150 is a support stand 180 that supportsa hydraulic pump 182. Hoses 184 connect the hydraulic pump 182 to thehydraulic cylinder 170 for controlling the extension and retraction ofthe piston 174. In practice, the hydraulic pump 182 may be relocated toany suitable position depending, for example, upon the layout of theparticular implementation of the manufacturing cell 100 and/or station102. Moreover, the controls for operating the hydraulic cylinder 170 maybe located on the hydraulic pump 182, on the support stand 180, or anyother suitable location, and can include operation by a computer,software or other suitable control arrangements.

Other conveyor arrangements may also be implemented, for example, byusing alternative technologies to assist the operator in movingcontainers 124 from the corresponding station-aisle interface 122 to thewelding area of the corresponding welding station 116.

The operator of a welding station 116 may work from one seesaw conveyor150 while the next order for that welding station 116 can be queued upon the second conveyor 150 as described more fully herein. The use ofthe two seesaw conveyors 150 assures that the operator will not have towait for the next order to be delivered. Thus, the trained stationoperator can continue working at a comfortable and steady pace. The twoconveyor approach may also maximize the time that the skilled stationoperator spends welding, thus reducing wasted time and inefficiencies.

Referring to FIG. 11, an exemplary schematic arrangement for organizingequipment for a welding station 116 is illustrated. A rack 190 ispositioned proximate to the end of the pair of seesaw conveyors 150. Therack 190 includes a face 192 that supports one or more hydraulic pumps182 to control the tilt of the respective seesaw conveyors 150 asdiscussed above, one or more control panels 194 and any othermiscellaneous controls, power supplies, electrical outlets, etc.

On top of the face 192 as shown is a shelf 196 that supports two weldingmachines 198. The welding machines 198 are positioned high enough on theshelf 196 that they are out of the way and do not inhibit movement ofthe station operators and others who perform work operations in thecorresponding welding station 116. The welding machines 198 may be fedfrom corresponding spools of wire 200A, which are supported by the face192. The spools 200A may be positioned in a convenient and ergonomicposition, e.g., lower than the welding machines 198 so that they can beeasily reached by a typical operator. For example, the spools 200A maybe positioned low enough for easy loading and unloading, such as wherethe weight of the spools 200A is a factor. Moreover, by positioning thespools 200A on the face 192 of the rack 190, the spools 200A arepositioned in a convenient access position for changeover, but arelocated out of the work area when welding, thus resulting in a clean andefficient work environment. Alternatively, to reduce the frequency ofwire changeover, weld wire may be provided in relatively large boxes ofwire 200B. A box of welding wire may weigh several hundred pounds andmay thus be provided on a roller/dolly arrangement to facilitatemovement of the boxes of wire 200B into position for use.

Extending from the top portion from the rack 190 is a pair of ducts 202coupled to, and extending from an extractor 204 for controlled airflow.The ducts 202 may include any number of joints, bends, flexible routing,etc., to address the needs of the work environment. Moreover, airflowthrough the ducts 202 and/or extractor 204 may pass through appropriatefilters and other treatments as the particular application dictates. Forexample, in a welding operation, the extractor 204 and correspondingducts 202 may be configured for fume and smoke extraction. The extractor204 may also be coupled, e.g., via suitable duct work, not shown, toremove the smoke and fumes to a remote location.

Accordingly, the single rack 190 supports the hydraulics and controlsand/or other suitable drive technologies for powering/controlling thetilt of the conveyors 150, stores the welding machines 198 out of theworkspace, positions the wire spools 200 in an ergonomically accessibleposition, and supports the necessary ducts 202 and associatedtechnologies. Depending upon the technology implemented at thecorresponding station, the rack 190 may also be used to store workimplement consumables, such as wire, rods, and utilities that supply thewelding station.

Referring to FIG. 12, a schematic side view of the system of FIG. 11 isillustrated. In FIG. 12, the storage unit 108 located above thestation-aisle interface 122 of the corresponding welding station 116 isshown in phantom lines to better illustrate the relative orientation ofthe features of the welding station 116. The ducts 202 may be positionedby an operator in the welding station 116 so as to provide airflow forfume and smoke removal at any desired location. For example, usingswivels, joints and other suitable configuring devices, the ducts 202may be positioned for extraction of welding fumes by positioning theducts 202 at appropriate locations.

Moreover, welding implements 206, which may include, for example, thetorch, welding controls/interface, etc., are coupled to the wire spoolsand corresponding welding machines 198 and are mounted on a boom 208that allows the welding equipment to be readily positioned at a desiredwork location by a station operator working in the corresponding weldingstation 116. For example, the welding boom 208 may be able to swivel,rotate, traverse up/down, in/out, etc., to position the weldingimplements 206 in any desired working position. Also, as shown, anindicator control 209 is shown on the inside face of the rack 190. Theindicator control 209 provides the necessary controls, such as buttons,switches, etc., for operating the indicator 130 associated with thatstation 102. The indicator control 209 can be positioned in anypractical location, such as where it may be convenient for an operatorto access and manipulate the indicator control 209 to set theappropriate status of the indicator 130 associated with that station 102described in greater detail herein.

Referring to FIG. 13A, fixtures 210, may be stored in the weldingstations 116, e.g., on work implement racks 212, and may be convenientlyaccessed and changed out. The fixtures 210 may be used for clamping,aligning, and/or fixturing parts to be welded in a work area of thewelding station 116 and may include, for example, correspondinghold-down dogs, bolt-down arm clamps, tapered pins, bending posts,clamps, riser blocks and other accessories, which are used to hold partsof a composite part (weldment) in place for making the weldment. Asingle work implement rack 212 and corresponding fixture 210 isillustrated for purposes of clarity. However, any number of fixtures210, work implement racks 212, etc., may be stored in each weldingstation 116.

As shown, a fixture 210 may be relocated from its storage location on acorresponding work implement rack 212 onto a table 214 for use withinthe welding station 116. Each moveable table 214 that is located in thewelding stations 116 may have, for example, a roller conveyor as atabletop 216 and each fixture 210 may have, for example, a bottomsurface that facilitates movement along the rollers of the table 214 fortransfer from its position on a work implement rack 212 to the table214. The table 214 may also include a height adjusting device 218, e.g.,a hydraulic lift that allows the height of the table top to be adjustedto accommodate the height of various storage shelves on the workimplement racks 212 and for orienting the fixture 210 to an appropriateheight for performing the required welding operations. For example, afoot operated pedal 219 may be used to raise/lower a lift cylinder 220coupled to the underside of the table top. The table 214 may alsoinclude casters or other suitable devices that allow the table 214 to beeasily repositioned to facilitate movement of the fixture 210 from thework implement rack 212 to a work area within the welding station 116.Still further, large and heavy fixtures may be permanently fixed to adedicated moveable table 214 rather than being stored on a workimplement rack 212.

Thus, when a fixture 210 is needed, the operator rolls a moveable table214 parallel to the work implement rack 212 at the location of thedesired fixture 210 and rolls the fixture 210 onto the table 214. Formovement of the fixture 210, it may be pinned or otherwise secured tothe table 214. The table 214 and corresponding fixture 210 can then betransported to an appropriate work area.

Referring to FIG. 13B, an alternative arrangement of a lifting table 214is illustrated. The table 214 shown in FIG. 13B does not have castersand is provided in a fixed location, e.g., as part of the cross conveyor132C in a press brake station 114. As shown, the table top may include aplurality of bearings as an alternative to cylindrical rollers. Also asshown, the height adjusting device 218 is implemented as ascissors-lifting arrangement, which may be utilized where theanticipated load is relatively heavy.

Referring to FIG. 14, certain stock items on a container 124 may belarge, heavy, awkward or otherwise inconvenient to transfer from theconveyor 150 to a corresponding work surface within the station 102. Forexample, a stock item 222 such as a part for a door or cover may beheavy and large. Accordingly, the container 124 may comprise a carouselcontainer. For example, as shown, the container 124 includes a baseportion 224 and a corresponding rotating carousel 226. As such, anoperator can remove all of the stock items 222 (8 as shown) from oneside of the conveyor 150 simply by rotating the carousel 226. Duringtransportation, the carousel 226 may lock, e.g., using a locking pin, tothe base portion 224 to prevent rotation thereof.

With reference to FIG. 15, another example of a container 124 isillustrated as being received at a welding station 116. Parts of thewelding station 116, such as the rack 190, and corresponding featurespreviously discussed have been removed for clarity. The stock items 222,e.g., large covers, would be cumbersome to manually lift off theconveyor 150 for positioning onto a suitable fixture 210 such as awelding jig that has been previously positioned on a table 228. Thus,the welding station 116 is equipped with a manipulator 140. As shown,the manipulator 140 is a hoist that allows an operator to lift and moveobjects within the station 116 so that they can be properly positioned.

For example, the hoist includes a transport 230 that can be controlledto traverse across a lateral support 232. The lateral support 232 iscoupled to posts 234 and may itself be controlled to traverse in anorthogonal (into and out of the page as shown) direction. As such, thetransport 230 can be moved anywhere within a horizontal, two dimensionalgrid which is bounded by the span of the lateral support 232 and thepositioning of the posts 234. To lift and lower objects in a verticaldirection, the hoist includes a linkage 236 that can extend and retractvertically with respect to the transport 230 and a correspondingconnector 238 that allows the hoist to attach to objects to be moved.The positioning of the transport 230 may be manually or electronicallycontrolled. Using the hoist, the operator can quickly reposition heavyobjects within the station with minimal effort.

As illustrated, one of the press brake stations and seven of the weldingstations have overhead manipulators 140 such as light duty overheadcranes to facilitate the manufacture of heavy parts with reducedexertion on the part of the welding station operators and assistants ifneeded. However, in practice, the use and location of overheadmanipulator(s) 140 within the manufacturing cell 100 may be determinedby the nature of the work being performed at each station 102.

Grinding Stations

Referring to FIG. 16, after weldments have been completed at one of thewelding stations 116, the weldments may be placed on containers that maybe transported, e.g., via the forklift truck 106 to a grinding station118 for appropriate grinding and finishing work. The two grindingstations 118 share a single conveyor 132G and operate, e.g., in a FIFOmanner substantially as described in greater detail herein. In theillustrated implementation of the manufacturing cell 100, the grindingstation 118 output is staged for exiting the manufacturing cell 100. Inan analogous manner to the other stations 102, all work implements,including tools, grinding wheels, etc., are stored at the grindingstations 118.

Miscellaneous Considerations

The manufacturing cell 100 may also include a dedicated inbound conveyor252 and/or a dedicated outbound conveyor 254. The inbound conveyor 252may be used to bring stock materials, raw materials, supplies and otherneeded objects into the manufacturing cell 100 from an external source.Likewise, the outbound conveyor 254 may be used to remove containersfrom the manufacturing cell 100 so that they can be transported to thenext process. For example, transport containers 124B, e.g., containersfor parts manufactured in the cell 100 that are to be removed from themanufacturing cell 100, may enter the cell via the inbound conveyor 252for replenishment. In an exemplary implementation, the output from thegrinding stations 118 comprises parts on transport containers 124B thatare placed on the outbound conveyor 254 for use outside themanufacturing cell 100.

According to an aspect of the present invention, when a cell container124A is moved to the outbound conveyor 254, a label that was temporarilyattached to the cell container 124A is removed, thus sending a genericcontainer 124 outside the manufacturing cell 100. The removed tag may bemaintained to track replenishment as is described in greater detailherein.

The inbound conveyor 252 may be used to return transport containers 124Bto the manufacturing cell 100 for replenishment. When a transportcontainer 124B (container holding product produced within the cell 100for use by a down stream process external to the manufacturing cell 100,e.g., a customer) is emptied and returned to the manufacturing cell 100for replenishment, the transport container 124B may include a shoporder, or a shop order may be otherwise associated with the returnedtransport container 124B, such as via an electronic system to identifythe stock to be replenished. However, very large transport containers124B may be delivered to the manufacturing cell 100 at a separatereceiving location and other arrangements may be implemented.

The containers 124 loaded onto the outbound conveyor 254 may be moved toa subsequent area, e.g., an outbound train 256, which includes aplurality of container storage spaces that can be towed away from themanufacturing cell 100. As such, an operator can periodically haul theoutbound train 256 away for appropriate relocating of the containersloaded thereon. As an example, a grinding operation may be the lastoperation performed by the manufacturing cell 100 on a given customeritem. As such, a container 124 that leaves the grinding station may exitto the outbound train 256.

Each station 102 may include containers including bins, buckets and thelike as well as other small parts storage areas within the station forconvenient access to commonly used parts that do not need to be storedon a container 124, including consumables such as paper forms and tags,supplies such as welding tips, etc. In this regard, the small partsstorage containers may be placed on an outbound conveyor of thecorresponding station 102 to designate that a replenishment operation isnecessary. Moreover, an indicator may be used to designate that tools orother work implements have been removed from their assigned storagelocations. For example, a green placard, light or other indicia canindicate that all tools are appropriately stored. A red placard, lightor other indicia can indicate that a tool has been removed from itsassigned storage location.

As noted in the examples above, when a cell container 124A is emptied,e.g., when a cell container 124A holding component parts that are usedup in a welding operation is returned from a work area of a weldingstation 116 to the corresponding station-aisle interface 122 for putaway, a replenishment operation is performed. In this regard, it may bethat certain operations may be required outside of the cell to implementthe replenishment function. For example, the stock items may need to belaser cut, or the stock items may need to be purchased, formed,fabricated or otherwise acquired. In this regard, a label 258 associatedwith the emptied cell container 124A may be scanned to trigger anautomatic replenishment workflow and corresponding replenishment order.Alternatively, a manually generated replenishment order may be createdto trigger a process outside the manufacturing cell 100 for the requiredstock items.

Referring to FIG. 17, until the necessary items are available, e.g., asindicated by receiving the stock items on the inbound conveyor 252, thelabel 258 is removed from the corresponding empty container 124 and thatlabel, or information corresponding to that label is stored on a stockboard 262 along with other labels 258. For example, the stock board 262may hold the magnetic labels described above with reference to FIG. 2.Alternatively, the stock board 262 can take other forms including anelectronic form. The container, now having its label removed, can bestored in a recycle location within the manufacturing cell 100. Asshown, the labels 128 are organized by day of the week, and labels 128that have been on the board 262 for over a week are distinguished.

When a stock item is received into the manufacturing cell 100, e.g., viathe inbound conveyor 252, the inbound container will include a shoporder associated therewith. The shop order is matched to a correspondinglabel 258 on the board 262. That label 258 is removed from the stockboard 262 and is attached to the cell container 124A received from theinbound lane, e.g., the inbound conveyor 252, and the stock handler putsthe replenished contents on the cell container 124A away at a suitablestorage unit 108, such as may be designated directly on the labelitself, or via other means, such as electronically driven replenishment,as determined by the stock handler, etc.

A visual inspection of the stock board 262 quickly indicates to the shopsupervisor, cell manager or other interested party, what items the cell100 is waiting on from an upstream process.

Exemplary Operation

With reference to FIG. 18, as the transport containers 124B are emptiedat a downstream process at some location outside the manufacturing cell100, the tag on the container, i.e., the barcode, label, RFID, memory orother identification/information storing or bearing technology on thecontainer may be correspondingly read, scanned, sensed, etc., at 302. Inresponse to reading the tag, a replenishment order is created for work,at least a portion of which is to be performed at the manufacturing cell100 and the order is appropriately distributed at 304. For example, theorder may be electronically generated and communicated to a desktopcomputer/printer, such as may be stationed at the management area, i.e.,the supervisor or team station 110, of the manufacturing cell 100.Alternatively, the order may be electronically communicated directly tothe truck 106, and may be output to a display and/or printer on thetruck 106. For example, using a wireless technology, the order may becommunicated directly to a wireless printer, display or other suitableprocessing device on the truck 106. Still further, the order may becommunicated to a gating operation upstream of the manufacturing cell100. Moreover, by electronically generating the order, appropriate datacan automatically feed an MRP and/or other manufacturing software, etc.

When the appropriate replenishment materials are located within themanufacturing cell 100, the stock handler operating the truck 106 picksup the order at 306, and moves containers 124 about the manufacturingcell 100 to facilitate manufacturing of the desired parts at 308. Whenprocessing within the manufacturing cell 100 is complete, one or morecontainers 124B, each having one or more parts thereon are deliveredoutside the manufacturing cell 100, e.g., to the outbound conveyor 254or other suitable location for use of the parts outside of themanufacturing cell 100.

For example, to manufacture a door for a materials handling vehicle, thestock handler may deliver a cell container 124A containing door blanksand an empty transport container 124B to an inbound conveyor at astation-aisle interface of a designated one of the press brake stations.The press brake station operator forms the door blanks to a desiredshape and relocates the formed doors to the transport container 124B.The cell container 124A is recycled and the transport container 124B,now holding the shaped door blanks, is moved to the outbound conveyor.

The stock handler picks up the transport container 124B at thestation-aisle interface of the press brake station and delivers thecontainer 124B to an inbound conveyor, e.g., a seesaw conveyor orientedfor inbound operation, at a station-aisle interface of a weldingstation. The stock handler may also retrieve one or more cell containers124A that hold components to be welded to the shaped door blanks fromvarious storage locations about the manufacturing cell, which are alsodelivered to the inbound conveyor of the welding station.

When the welding operation is complete, all containers are deliveredback to the station-aisle interface, e.g., by orienting the seesawconveyor for outbound conveyance. If a cell container 124A is returnedempty, a replenishment operation is triggered to replace those consumedcomponents. Otherwise, the cell containers 124A are returned to storagelocations within the manufacturing cell.

The transport container 124B, which now holds one or more formed andwelded doors, is either relocated to an outbound conveyor of themanufacturing cell, or it is delivered to the conveyor at thestation-aisle interface of the grinding stations for finishing work.After the grinding operations are complete, the transport container 124Bis moved to the manufacturing cell outbound conveyor so that the doorsmay be used in a downstream process outside of the manufacturing cell.

Depending upon the workload and number of active stations in the cell,station operators may move about from one station to another, such asdepending upon the particular component(s) to be manufactured/assembled.Alternatively, station operators can quickly change over stations forproduction of different parts. In this regard, a labor calculator and/orother management tools may be utilized to calculate the labor needswithin the manufacturing cell 100, and to predict station operatorrequirements based upon production, assembly, service requirements, etc.

Each press brake station 114 may be required to produce multiple partsfor one or more product lines both for the cell and for othermanufacturing operations outside the cell. In order to enable a varietyof parts to efficiently flow through the press brake stations 114, aquick die change procedure is illustrated in the flow charts of FIGS. 19and 20. Each actively working press brake station may be operated by aproduction tender and a primary operator. In this regard, a singletender may service, for example, all actively running press brakestations. The tender's responsibility includes assisting the primaryoperator during a die changeover. The flow chart of FIG. 19 provides anexemplary method 320 that organizes the tender's actions so that alltooling and gauging that is required to run a job is ready to go beforethe changeover is to take place, i.e., pre-changeover activity.

The tender obtains the tools at 322 and prepares necessary gauges at324. The tender then stages the retrieved tools and gauges in anappropriate location, e.g., beside the corresponding press brake at 326.The tender then pulls the tools from the previous job out from the pressat 328 and puts the newly obtained tools in the press at 330. The tenderclamps and seats the tooling at 332 and puts the previously used toolsaway at 334.

With reference to FIG. 20, a method 340 illustrates an exemplarystandard work procedure for a changeover for the primary operator. Theprimary operator lowers the press to an unload position at 342 and toolsare unclamped at 344. The primary operator moves the completed parts tothe outbound conveyor at 346 and new parts are positioned with respectto the die at 348. The correct program is called up on the press brakeat 350 and the backstops are set at 352. The press brake machine cycleis started at 354 and a dry run press is executed at 356.

The press changeover procedure may be handled differently, dependingupon the application, e.g., due to the size of the required tools. Forheavier tools, the tool sets may be equipped with an air bearing toeasily load and unload the large tools. The air bearing may comprise aspecially designed bottom plate on the tool that will float the tool ona cushion of air. The large tooling is stored on a table to allow thetool to float in the press without requiring strenuous lifting asdescribed more fully herein.

The flowchart and block diagrams in the figures illustrate thearchitecture, functionality, and operation of possible implementationsof systems and methods according to various embodiments of the presentinvention. In some alternative implementations, the operations noted inthe blocks may occur out of the order noted in the figures. For example,two blocks shown in succession may, in fact, be executed substantiallyconcurrently or in the reverse order.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises”and/or “comprising,” when used in this specification, specify thepresence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, integers, steps, operations, elements,components, and/or groups thereof.

The description of the present invention has been presented for purposesof illustration and description, but is not intended to be exhaustive orlimited to the invention in the form disclosed. Many modifications andvariations will be apparent to those of ordinary skill in the artwithout departing from the scope and spirit of the invention.

Having thus described the invention of the present application in detailand by reference to embodiments thereof, it will be apparent thatmodifications and variations are possible without departing from thescope of the invention defined in the appended claims.

1. A method of manufacturing parts using a manufacturing cell comprises:storing components to be used during manufacture on cell containers;storing said cell containers in storage units that are located along amain aisle in cooperation with a plurality of stations arranged in tworows such that said main aisle passes between said two rows, whereineach of said plurality of stations has a station-aisle interface thatprovides an interaction area to said main aisle and is configured suchthat a corresponding station operator is capable of performing apredefined function associated with said manufacturing cell; receivingan order to manufacture a part; using a guided forklift truck totraverse said main aisle without requiring steering control of a stockhandler operating said forklift truck to relocate said cell containersfrom said storage units to designated ones of said of station-aisleinterfaces to trigger inbound workflows to corresponding ones of saidplurality of stations, and removing containers from said designated onesof said plurality of station-aisle interfaces when work is completed atsaid corresponding ones of said plurality of stations.
 2. The methodaccording to claim 1, further comprising: enabling a visual indicatorlocated at a position that is visible to said stock handler operatingsaid guided forklift truck to indicate the status of a correspondingstation.
 3. The method according to claim 2, wherein said visualindicator is located at a position that is visible to said stock handleroperating said guided forklift truck to indicate the status of acorresponding station further comprises: setting said indicator to afirst color to indicate that a corresponding station is busy operating,and setting said indicator to a second color to indicate that saidcorresponding station is in need of said stock handler.
 4. The methodaccording to claim 2, further comprising: positioning said indicatoralong said main aisle adjacent to a corresponding station-aisleinterface of each station.
 5. The method according to claim 1, whereinsaid storing said cell containers in storage units that are locatedalong a main aisle in cooperation with a plurality of stationscomprises: configuring a storage unit as at least one rack above saidstation-aisle interface of a corresponding station; wherein said storingsaid cell containers in storage units that are located along a mainaisle further comprises storing at least one cell container that hascomponents associated with a function assigned to said correspondingstation on a rack above said station-aisle interface.
 6. The methodaccording to claim 5, further comprising: assigning container tags toeach cell container by: identifying the contents of the cell container;specifying a location to store said cell container; and specifying howto replenish said cell container.
 7. The method according to claim 1,further comprising generating a replenishment operation when said stockhandler picks up an empty one of said cell containers from a station by:using said guided forklift truck to deliver said empty one of said cellcontainers to a designated area; removing a detachable tag from saidempty one of said cell containers; and triggering a gating operation toreplenish the contents of said empty one of said cell containers.
 8. Themethod according to claim 7, further comprising: storing said detachabletag which was removed from said empty cell container on a stock boardthat is visible from said manufacturing cell.
 9. The method according toclaim 8, further comprising: receiving a replenishment cell container onan inbound conveyor of said manufacturing cell; installing saiddetachable tag onto said replenishment container; picking up saidreplenishment cell container with said guided forklift truck; andreturning said replenishment cell container to a suitable storage unit.10. The method according to claim 1, further comprising: distinguishingbetween cell containers that hold components for use within saidmanufacturing cell and transport containers that are used to store partsmanufactured within said manufacturing cell and which are delivered foruse outside of said manufacturing cell.
 11. The method according toclaim 10, further comprising: reading information from a transportcontainer that has been emptied during a process that is downstream andoutside of said manufacturing cell; creating an order to replenish stocksimilar to the stock that was associated with said emptied transportcontainer for replenishment from said manufacturing cell; communicatingsaid order to a stock handler operating a guided forklift truck withinsaid cell; utilizing said guided forklift truck to traverse said aisleto pull one or more cell containers for delivery to at least oneassigned station within said cell for work thereon; manufacturingreplenishment stock that is stored on a new transport container; anddelivering said replenishment stock on said new transport container fromsaid manufacturing cell to a subsequent process.
 12. The methodaccording to claim 11, wherein at least one station comprises a pressbrake station and said method includes changeover activity for saidpress brake station preformed by a production tender comprising:obtaining the necessary work implements associated with a new part to beprocessed; preparing necessary gauges for setting up a correspondingbrake press; staging work implements and gauges relative to acorresponding brake press; pulling tools out of said corresponding brakepress from a previous job if necessary; putting new tools in saidcorresponding brake press; clamping and seating said new tools in saidbrake press; and putting tools used from previous job away within saidpress brake station.
 13. The method according to claim 12, wherein saidmethod includes changeover activity for said press brake performed by apress operator comprising: lowering said corresponding press brake to anunload position; unclamping said tools in said press brake; movingcompleted parts to an outbound conveyor associated with said press brakestation; positioning new parts in a die associated with said pressbrake; calling up a required program on said press brake; settingbackstops of said press brake; starting a machine cycle of said pressbrake; and executing a dry run press operation of said press brake. 14.A method of manufacturing parts using a manufacturing cell comprises:laying out said cell to have a main aisle and a plurality of stationsarranged in two rows such that said main aisle passes between said tworows; configuring each of said plurality of stations to have astation-aisle interface that provides an interface area to said mainaisle so that a corresponding station operator is capable of performinga predefined function associated with said manufacturing cell at astation work area; locating a plurality of storage units within saidcell along said main aisle, each storage unit dimensioned to store atleast one cell container that holds one or more components associatedwith work flowing through said cell; using a guided forklift truck totraverse said main aisle without requiring steering control of a stockhandler operating said forklift truck to relocate cell containers fromsaid storage units to designated ones of said station-aisle interfacesto trigger inbound workflows to corresponding ones of said plurality ofstations, and to remove containers from said designated ones of saidplurality of station-aisle interfaces when work is completed at saidcorresponding ones of said plurality of stations; using two conveyorseach having a platform that is tiltable in at least one of saidplurality of stations; configuring said conveyors to have an endproximate to said station-aisle interface in said at least one of saidplurality of stations; tilting said conveyors in a first position sothat a container delivered by said forklift truck from said aisle tosaid platform is biased by gravity to move toward said station workarea; and tilting said conveyor to a second position so that a containerdelivered from said station work area to said platform is biased bygravity to move toward said aisle for pickup by said forklift truck sothat each of said two conveyors can be used to receive and returncontainers between said station work area and the station-aisleinterface.
 15. The method according to claim 14 further comprising:configuring one of said plurality of storage units as at least one rackabove said station-aisle interface of a corresponding station; andstoring at least one cell container that has components associated witha function assigned to said corresponding station on a rack above saidstation-aisle interface.
 16. The method according to claim 14, furthercomprising generating a replenishment operation when said stock handlerpicks up an empty one of said cell containers from a station by: usingsaid guided forklift truck to deliver said empty one of said cellcontainers to a designated area; removing a detachable tag from saidempty one of said cell containers; and triggering a gating operation toreplenish the contents of said empty one of said cell containers. 17.The method according to claim 16, further comprising: storing saiddetachable tag which was removed from said empty cell container on astock board that is visible from said manufacturing cell.
 18. The methodaccording to claim 17, further comprising: receiving a replenishmentcell container on an inbound conveyor of said manufacturing cell;installing said detachable tag onto said replenishment container;picking up said replenishment cell container with said guided forklifttruck; and returning said replenishment cell container to a suitablestorage unit.
 19. The method according to claim 14, further comprising:distinguishing between cell containers that hold components for usewithin said manufacturing cell and transport containers that are used tostore parts manufactured within said manufacturing cell and which aredelivered for use outside of said manufacturing cell.
 20. The methodaccording to claim 19, further comprising: reading information from atransport container that has been emptied during a process that isdownstream and outside of said manufacturing cell; creating an order toreplenish stock similar to the stock that was associated with saidemptied transport container for replenishment from said manufacturingcell; communicating said order to a stock handler operating a guidedforklift truck within said cell; utilizing said guided forklift truck totraverse said aisle to pull one or more cell containers for delivery toat least one assigned station within said cell for work thereon;manufacturing replenishment stock that is stored on a new transportcontainer; and delivering said replenishment stock on said new transportcontainer from said manufacturing cell to a subsequent process.